Manufacturing of solid oxide fuel cells: Novel ceramic processes

This study explores the manufacturing of solid oxide cells (SOCs) and introduces innovative ceramic processes essential to their production. The research primarily focuses on the manufacturing and characterization of porous supports manufactured from yttria-stabilized zirconia (3YSZ). The methodology involves a pioneering technique employing digital deposition of dry powders and ink-jet printing followed by pressing. Solid oxide cells (SOCs) stand as advanced ceramic devices employed in diverse electrochemical applications, including solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs). SOFCs exhibit distinct advantages over alternative fuel cell types, boasting high efficiency, fuel adaptability, and minimal emissions. They demonstrate the capability to operate with various fuels, including hydrogen, natural gas, and biogas, suggesting their potential to supersede traditional power generation technologies due to heightened efficiency and reduced environmental impact. Notably, these cells are reversible and can facilitate hydrogen gas production through steam electrolysis (SOEC). This research focuses on formulating and testing diverse compositions of porous supports, incorporating distinct types, shapes, and sizes of pore formers. Strength and stiffness properties of the sintered bodies are assessed using advanced techniques, encompassing scanning electron microscopy, mercury porosimetry, ultrasound methodologies for determining Young's modulus, and measuring mechanical bending strength. Results elucidate a clear correlation between increased total porosity and an exponential decrease in Young's modulus and strength. Meticulously manufactured and characterized 3YSZ samples undergo comprehensive analysis to evaluate their suitability as support structures in solid oxide electrolysis or fuel cell applications. The findings from this research offer invaluable insights for designing and developing porous materials utilizing the proposed innovative processes, with the potential to enhance the production of cells for state-of-the-art electrochemical technologies.